Cutter assembly with at least one island and a method of manufacturing a cutter assembly

ABSTRACT

A cutter assembly and a method of making the cutter assembly are disclosed. A method of fabricating a cutting element having at least one island structure in at least one pocket of a substrate may comprise steps of building the substrate with at least one pocket; putting the at least one island into the at least one pocket in the substrate to form an assembly, the at least one island is not in a final state, wherein in the final state, chemical composition, shape, phase distribution and content, density and mechanical properties are finalized without changes; and subjecting the assembly to a final fabrication process to form the said cutting element and achieve the final state of the cutting element and at least one island in at least one pocket.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation-in-part of, and claiming priorityunder 35 U.S.C. §120 to, U.S. patent application Ser. No. 13/339,483,filed on Dec. 29, 2011, U.S. patent application Ser. No. 13/339,474,filed on Dec. 29, 2011, U.S. patent application Ser. No. 13/339,838,filed on Dec. 29, 2011, U.S. patent application Ser. No. 13/339,854,filed on Dec. 29, 2011.

FIELD

The present disclosure relates to a cutter assembly with at least oneisland. More particularly, the present disclosure relates a cutterassembly that can include a substrate and at least one island disposedin the substrate.

BACKGROUND

In the discussion of the background that follows, reference is made tocertain structures and/or methods. However, the following referencesshould not be construed as an admission that these structures and/ormethods constitute prior art. Applicants expressly reserve the right todemonstrate that such structures and/or methods do not qualify as priorart.

Cutters can be subject to abrasion which can shorten the working life ofthe cutter. Thus, there is a need in the art for a cutter assembly thatcan provide higher abrasion resistance or longer cutter life.

SUMMARY

Exemplary embodiments provide a cutter assembly and a method ofmanufacturing a cutter assembly. In one exemplary embodiment, a methodof fabricating a cutting element having at least one island structure inat least one pocket of a substrate may comprise steps of building thesubstrate with at least one pocket; putting the at least one island intothe at least one pocket in the substrate to form an assembly, the atleast one island is not in a final state, wherein in the final state,chemical composition, shape, phase distribution and content, density andmechanical properties are finalized without changes; and subjecting theassembly to a final fabrication process to form the said cutting elementand achieve the final state of the cutting element and at least oneisland in at least one pocket.

In another exemplary embodiment, a method of fabricating a cuttingelement having at least one island structure in at least one pocket of asubstrate may comprise steps of putting at least one island into atleast one pocket in a substrate to form an assembly, the at least oneisland is not in a final state, wherein in the final state, chemicalcomposition, shape, phase distribution and content, density andmechanical properties are finalized without changes; and subjecting theassembly to a high temperature high pressure sintering process to formthe said cutting element and achieve the final state of the cuttingelement and at least one island in at least one pocket.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWING

The following detailed description can be read in connection with theaccompanying drawings in which like numerals designate like elements andin which:

FIG. 1 is a perspective view of a cutter assembly with at least oneisland in accordance with an embodiment.

FIG. 2 is a side view of the cutter assembly with at least one islandshown in FIG.

FIG. 3 is a sectional side view of the cutter assembly with at least oneisland shown in FIG. 1.

FIG. 4 is a top view of the cutter assembly with at least one islandshown in FIG.

FIG. 5 is a perspective view of a cutter assembly with at least oneisland of an alternate construction.

FIG. 6 is a side view of the cutter assembly with at least one island ofan alternate construction shown in FIG. 5.

FIG. 7 is a sectional side view of the cutter assembly with at least oneisland of an alternate construction shown in FIG. 5.

FIG. 8 is a perspective view of a cutter assembly with at least oneisland of an alternate construction.

FIG. 9 is a side view of the cutter assembly with at least one island ofan alternate construction shown in FIG. 8.

FIG. 10 is a sectional side view of the cutter assembly with at leastone island of an alternate construction shown in FIG. 8.

FIG. 11 is a perspective view of a cutter assembly with at least oneisland of an alternate construction.

FIG. 12 is a side view of the cutter assembly with at least one islandof an alternate construction shown in FIG. 11.

FIG. 13 is a sectional side view of the cutter assembly with at leastone island of an alternate construction shown in FIG. 11.

FIG. 14 is a top view of a cutter assembly with at least one island ofan alternate construction.

FIG. 15 is a top view of a cutter assembly with at least one island ofan alternate construction.

FIG. 16 is a top view of a cutter assembly with at least one island ofan alternate construction.

FIG. 17 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 18 is a side view of the cutter assembly with at least one islandshown in FIG. 17.

FIG. 19 is a sectional side view of the cutter assembly with at leastone island shown in FIG. 17.

FIG. 20 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 21 is a side view of the cutter assembly with at least one islandshown in FIG. 20.

FIG. 22 is a sectional side view of the cutter assembly with at leastone island shown in FIG. 20.

FIG. 23 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 24 is a side view of the cutter assembly with at least one islandshown in FIG. 23.

FIG. 25 is a sectional side view of the cutter assembly with at leastone island shown in FIG. 23.

FIG. 26 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 27 is a side view of the cutter assembly with at least one islandshown in FIG. 26.

FIG. 28 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 26.

FIG. 29 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 30 is a side view of the cutter assembly with at least one islandshown in FIG. 29.

FIG. 31 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 29.

FIG. 32 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 33 is a side view of the cutter assembly with at least one islandshown in FIG. 32.

FIG. 34 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 32.

FIG. 35 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 36 is a side view of the cutter assembly with at least one islandshown in FIG. 35.

FIG. 37 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 35.

FIG. 38 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 39 is a side view of the cutter assembly with at least one islandshown in FIG. 38.

FIG. 40 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 38.

FIG. 41 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 42 is a side view of the cutter assembly with at least one islandshown in FIG. 41.

FIG. 43 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 41.

FIG. 44 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 45 is a side view of the cutter assembly with at least one islandshown in FIG. 44.

FIG. 46 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 44.

FIG. 47 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 48 is a side view of the cutter assembly with at least one islandshown in FIG. 47.

FIG. 49 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 47.

FIG. 50 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 51 is a side view of the cutter assembly with at least one islandshown in FIG. 50.

FIG. 52 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 50.

FIG. 53 is a perspective view of a cutter assembly with at least oneisland in accordance with an alternate construction.

FIG. 54 is a side view of the cutter assembly with at least one islandshown in FIG. 53.

FIG. 55 is an exploded, sectional side view of the cutter assembly withat least one island shown in FIG. 53.

FIG. 56 is a flowchart of a method of manufacturing a cutter with atleast one island in accordance with an embodiment.

FIG. 57 is a flowchart of a method of manufacturing a cutter with atleast one island in accordance with an alternate construction.

DETAILED DESCRIPTION

Referring to FIGS. 1-56, embodiments can provide a cutter assembly 100,200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400,1500, 1600, 1700, 1800, and 1900 with higher abrasion resistance, longerlife, better toughness, and/or thermal stability. Embodiments canutilize, for example, fully leached polycrystalline diamond, which canhave significantly better thermal stability up to approximately 1,000°C. When fully leached polycrystalline diamond is used and coupled with,for example, a cobalt-tungsten carbide, embodiments can also providehigher strength at the interface between fully leached polycrystallinediamond and cobalt-tungsten carbide. Embodiments can also provide amethod of manufacturing a cutter assembly 100 . . . 1900, that includes,for example, a fully leached polycrystalline diamond, which is coupledto, for example, cobalt-tungsten carbide securely and economically.

The cutter assembly 100 . . . 1900 can comprise a substrate 102, 202,302, 402, 502, 602, 702, 802, 902, 1002, 1102, 1202, 1302, 1402, 1502,1602, 1702, 1802, and 1902 at least one island 150 a, 150 b, 250, 350,450, 550, 650, 750, 850, 950, 1050, 1150, 1250, 1350, 1450, 1550, 1650,1750, 1850, and 1950 disposed in the substrate 102 . . . 1902. The atleast one island 150 a . . . 1950 can be disposed in the substrate 102 .. . 1902. The substrate 102 . . . 1902 can have a surface 104, 204, 304,404, 504, 604, 704, 804, 904, 1004, 1104, 1204, 1304, 1404, 1504, 1604,1704, 1804, and 1904. The surface 104 . . . 1904 can receive one or moreof the islands 150 a . . . 1950. In other constructions of the cutterassembly 100 . . . 1900, the substrate 102 . . . 1902 can have aplurality of surfaces 104 . . . 1904, and each one of the plurality ofsurfaces 104 . . . 1904 can receive one or more of the islands 150 a . .. 1950.

The at least one island 150 a . . . 1950 can be disposed in thesubstrate 102 . . . 1902 such that the at least one island 150 a . . .1950 is spaced apart from another island 150 a . . . 1950 in oneexemplary embodiment. In another exemplary embodiment, islands 150 a . .. 1950 may be disposed in the substrate 102 . . . 1902 such that theisland 150 a . . . 1950 may be integrated to form a semi continuousshape, for example. The substrate 102 . . . 1902 can be made fromtungsten carbide cobalt (WC—Co), a diamond-silicon carbide compositematerial, binderless carbide, or polycrystalline diamond (PCD), or someother suitable materials. One example of a diamond-silicon carbidecomposite material is commercially available as VERSIMAX manufactured byDiamond Innovations, Inc., Worthington, Ohio USA. Binderless can referto tungsten carbide composites with less amount of metal binder phasethan a metal-WC composite cermet material, such as Co—WC compositecermet material, Ni—WC composite cermet material, Fe—WC composite cermetmaterial, and the like. Examples of binderless carbide can include acermet of tungsten carbide binded with a molybdenum metal and a lowmetal content of about 1 wt % to about 2 wt %. Binderless carbide canalso include a type of tungsten carbide sintered with low metal content,such as about 1 wt % to about 2 wt %, and a binding phase that is mainlyeta-phase (Co₃W₃O₆).

The at least one island 150 a . . . 1950 can be made frompolycrystalline diamond (PCD), diamond, cubic boron nitride (CBN),polycrystalline cubic boron nitride (PCBN), or a diamond-silicon carbidecomposite material a cemented carbide, a ceramic, a metal, a metalalloy, and/or combinations thereof; a substrate; an optional coatinglayer, wherein the coating layer may be in direct contact with theisland or the substrate, and the coating layer may be continuous ordiscontinuous. One example of a diamond-silicon carbide compositematerial is commercially available as VERSIMAX.

The at least one island 150 a . . . 1950 can be a thermally stablematerial. The thermally stable material may be made by leaching catalystfrom polycrystalline diamond in an acid solution, for example. If the atleast one island 150 a . . . 1950 is made from PCD, the at least oneisland 150 a . . . 1950 made from PCD can be fully leached, partiallyleached, or unleached. In a construction of the cutter assembly 100 thatincludes fully leached PCD, the cutter assembly 100 . . . 1900 canprovide thermal stability.

The at least one island 150 a . . . 1950 can be coated. The coatingmaterial can comprise a metal, a metal alloy, a compound of the metaland/or combination of series thereof. The metal may comprise tungsten,titanium, niobium, zirconium, tantalum, vanadium, chromium, ormolybdenum. The coating can be applied upon at least a portion of the atleast one island 150 a . . . 1950 via a coating method that can comprisephysical vapor deposition, chemical vapor deposition, sputtering,evaporation, electroless plating, electroplating, and/or combinations orseries thereof. The coating layer can have a thickness of about 0.1 μmto about 100 μm.

The at least one island 150 a . . . 1950 can have a casing. In someconstructions of the cutter assembly 100 . . . 1900, the at least oneisland 150 a . . . 1950 can be press fit into the casing. The casing canbe a metal casing. The metal casing can provide a medium between the atleast one island 150 a . . . 1950 and the substrate 102 . . . 1902 andmay help to manage the deformation and stress condition between the atleast one island 150 a . . . 1950 and the substrate 102 . . . 1902. Thecasing layer can have a thickness of about 0.1 μm to about 100 μm. Inanother embodiment the at least one island 150 . . . 1950 can bedirectly fitted into the substrate 102 . . . 1902, and thus, no casingmay be needed. In another exemplary embodiment, the island 150 a . . .1950 may also be coated with ceramics or CVD diamond or diamond likecarbon, for example.

The at least one island 150 a . . . 1950 can be coupled to the substrate102 . . . 1902. The at least one island 150 a . . . 1950 can be coupledto the substrate 102 . . . 1902 by, for example, gluing, brazing,bonding, welding, clamping, mechanical locking, or some other suitablecoupling. An embodiment can include a method for brazing an island. Themethod for brazing the island can comprise: brazing a coated island to asubstrate, wherein the island material can comprise a cemented carbide,a polycrystalline cubic boron nitride (cBN) superabrasive, a ceramic, ametal, a metal alloy, and/or combinations thereof; a substrate; anoptional coating layer, wherein the coating layer may be in directcontact with the island or the substrate, and the coating layer may becontinuous or discontinuous. The brazing step may comprise: heating atleast one of the braze metal, the coating layer, and the substrate, to atemperature above a liquidus temperature sufficient to melt the brazemetal; and bringing the melted braze metal into contact with both theisland and the substrate and optionally the coating to form a brazemetal layer. The braze metal layer can comprise silver, copper,magnesium, nickel, zinc, palladium, chromium, boron, titanium, tin,silicon, or an alloy or composite thereof. The substrate can comprise asecond island, and the second island materials can comprise a cementedcarbide, a polycrystalline cubic boron nitride (cBN) superabrasive, aceramic, a metal, a metal alloy, and/or combinations thereof. In anembodiment of the method, the first and second island material may eachindependently comprise a single crystal diamond, a chemical vapordeposition diamond, a silicon carbide bonded diamond composite, acobalt-polycrystalline diamond composite, a thermally-stable diamondcomposite, and/or combinations thereof. In an embodiment of the method,the coating metal may comprise tungsten, titanium, niobium, zirconium,tantalum, vanadium, chromium, molybdenum and/or combinations thereof. Inan embodiment of the method, the coating metal may comprise at least onerefractory metal and, optionally, at least one non-refractory metal. Inan embodiment of the method, the refractory metal carbide may compriseat least one metal of the refractory metal or the refractory metalalloy. In an embodiment of the method, the refractory metal layer mayhave a thickness of about 0.1 μm to about 100 μm. In an embodiment ofthe method, the brazing step may comprise applying a heat source to heatat least the braze metal to the temperature of from about 500° C. toabout 1000° C. In an embodiment of the method, the heat source may be atleast one of a torch, a furnace, a microwave device, an arc welder, alaser, or an induction coil. In an embodiment of the method, the heatsource may be an induction coil; and the temperature is maintained fromabout 700° C. to about 900° C. for a time period of at least about 5seconds. In an embodiment of the method, the brazing step may beperformed under ambient air pressure and in air. In another embodimentof the method, the brazing step may be performed under flowing orstagnant inert protection gas or gas mixtures.

The substrate 102 . . . 1902 can have any suitable shape. For example,in FIGS. 1-13, 17-34, and 38-52, the substrate 102 . . . 402, 802 . . .1302, and 1502 . . . 1802 can have a generally cylindrical shape. Inother constructions of the cutter assembly 100 . . . 1900, the substrate102 . . . 1902 can have a shape that is not generally cylindrical. Forexample, FIGS. 35-37 and 53-55 show a substrate 1402 and 1902 thatincludes a concavity.

The at least one island 150 a . . . 1950 can have any suitable shape. Asshown in FIGS. 1 to 13, 23-28, and 38-55, the at least one island 150,250, 350, 450, 1050, 1150, 1550, 1650, 1750, 1850, and 1950 can have agenerally cylindrical shape. As shown in FIGS. 14-19, the at least oneisland 550, 650, 750, and 850 can have a cross-sectional shape that isnot substantially circular. As shown in FIGS. 29-37, the at least oneisland 1250, 1350, and 1450 can be have a ring shape or be a pluralityof rings.

Turning to FIGS. 1-4, the cutter assembly 100 can have a substrate 102with a generally cylindrical shape. The substrate 102 can have a surface104. The surface 104 can be an end surface. The substrate 102 can alsohave a flank surface 106. The surface 104 can be substantiallyperpendicular to the flank surface 106. The flank surface 106 can meetthe surface 104 so that a common boundary between the surface 104 andthe flank surface 106 defines a peripheral edge 108 of the surface 104.The surface 104 can be a substantially planar surface. The flank surface106 can provide the substrate 102 with a generally circularcross-sectional shape. In other embodiments, the substrate 102 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 102 can include a pocket 110. The pocket 110 can have anopening 112. The opening 112 can be disposed on the surface 104 of thesubstrate 102. The pocket 110 can extend from the opening 112 on thesurface 104 to an interior of the substrate 102. The pocket 110 can havea shape that can receive at least a portion of the at least one island150.

Referring to FIGS. 2 a and 3 a, the at least one island 150 a can have agenerally cylindrical shape. The at least one island 150 a can have anend surface 152, a flank surface 154, and an opposite end surface 156.The end surface 152 can be a planar surface that can be substantiallyperpendicular to the flank surface 154. The opposite end surface 156 canalso be a planar surface that is substantially perpendicular to theflank surface 154. The at least one island 150 a can be disposed in thepocket 110 of the substrate 102. The at least one island 150 a can bedisposed in the pocket 110 of the substrate 102 so that the end surface152 of the at least one island 150 a is substantially co-planar withsurface 104 of the substrate 102, the flank surface 154 extends into theinterior of the substrate 102, and the opposite end surface 156 isdisposed within the interior of the substrate 102. The end surface 152can be a cutting surface, or the end surface 152 and the flank surface154 together can form a cutting surface.

Referring to FIGS. 2 b and 3 b, the at least one island 150 b can have agenerally cylindrical shape. The at least one island 150 b can have anend surface 152, a flank surface 154, and an opposite end surface 156.However, unlike the at least one island 150 a, the at least one island150 b can also include an edge 158. The edge 158 can be rounded or achamfer. The edge 150 may relieve stress. The end surface 152 can be aplanar surface that can be substantially perpendicular to the flanksurface 154. In one exemplary embodiment, the opposite end surface 156can also be a planar surface that is substantially perpendicular to theflank surface 154. In another exemplary embodiment, the island 150 b mayextend through the substrate and there may be no surface 156. The atleast one island 150 b can be disposed in the pocket 110 of thesubstrate 102. The at least one island 150 b can be disposed in thepocket 110 of the substrate 102 so that the end surface 152 of the atleast one island 150 a is substantially co-planar with surface 104 ofthe substrate 102, the flank surface 154 extends into the interior ofthe substrate 102, and the opposite end surface 156 is disposed withinthe interior of the substrate 102. Because the at least one island 150 bcan include the edge 158, the pocket 110 can include a complementaryshape that can receive the edge 158. The end surface 152 can be acutting surface, or the end surface 152 and the flank surface 154together can form a cutting surface.

In the construction shown in FIGS. 1-4, there are three islands 150spaced equally apart from each other and equidistant from a center ofthe surface 104. However, in other constructions, there may be more orless than the three islands 150 shown. Also, the exact position of eachof the island 150 with respect to each other or the center of thesurface 104 can be different from that shown in FIGS. 1-4. Also, theexact size of the islands 150 can be different. The exact number andsize of islands 150 and the exact position for each of the islands 150can depend on, for example, the application of the cutter assembly 100.

Turning to FIGS. 5-7, the cutter assembly 200 may have a substrate 202with a generally cylindrical shape. The substrate 202 may have a surface204. The surface 204 can be an end surface. The substrate 202 can alsohave a flank surface 206. The surface 204 can be substantiallyperpendicular to the flank surface 206. The flank surface 206 can meetthe surface 204 so that a common boundary between the surface 204 andthe flank surface 206 defines a peripheral edge 208 of the surface 204.The surface 204 can be a substantially planar surface. The flank surface206 can provide the substrate 202 with a generally circularcross-sectional shape. In other embodiments, the substrate 202 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 202 can include a pocket 210. The pocket 210 can have anopening 212. The opening 212 can be disposed on the surface 204 of thesubstrate 202. The pocket 210 can extend from the opening 212 on thesurface 204 to an interior of the substrate 202. The pocket 210 can havea shape that can receive at least a portion of the at least one island250.

The at least one island 250 can have a generally cylindrical shape. Theat least one island 250 can have an end surface 252, a flank surface254, and an opposite end surface 256. Unlike the at least one island 150shown in FIGS. 1-4, the end surface 252 can include a dome shape. Theopposite end surface 256 can be a planar surface that can besubstantially perpendicular to the flank surface 254. The at least oneisland 250 can be disposed in the pocket 210 of the substrate 202. Theat least one island 250 can be disposed in the pocket 210 of thesubstrate 202 so that the end surface 252 of the at least one island 250protrudes away from the surface 204 of the substrate 202 and away fromthe interior of the substrate 202, the flank surface 254 extends intothe interior of the substrate 202, and the opposite end surface 256 isdisposed within the interior of the substrate 202. The end surface 252can be a cutting surface, or the end surface 252 and the flank surface254 together can form a cutting surface.

In the construction shown in FIGS. 5-7, there are three islands 250spaced equally apart from each other and equidistant from a center ofthe surface 204. However, in other constructions, there may be more orless than the three islands 250 shown. Also, the exact position of eachof the island 250 with respect to each other or the center of thesurface 204 may be different from that shown in FIGS. 5-7. Also, theexact size of the islands 250 can be different. The exact number andsize of islands 250 and the exact position for each of the islands 250can depend on, for example, the application of the cutter assembly 200.

Turning to FIGS. 8-10, the cutter assembly 300 can have a substrate 302with a generally cylindrical shape. The substrate 302 can have a surface304. The surface 304 can be an end surface. The substrate 302 can alsohave a flank surface 306. The surface 304 may be substantiallyperpendicular to the flank surface 306. The flank surface 306 can meetthe surface 304 so that a common boundary between the surface 304 andthe flank surface 306 defines a peripheral edge 308 of the surface 304.The surface 304 can be a substantially planar surface. The flank surface306 can provide the substrate 302 with a generally circularcross-sectional shape. In other embodiments, the substrate 302 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 302 can include a pocket 310. The pocket 310 can have anopening 312. The opening 312 can be disposed on the surface 304 of thesubstrate 302. The pocket 310 can extend from the opening 312 on thesurface 304 to an interior of the substrate 302. The pocket 310 can havea shape that can receive at least a portion of the at least one island350. The pocket 310 may be angled with respect to the substrate in oneexemplary embodiment.

The at least one island 350 can have a generally cylindrical shape. Theat least one island 350 can have an end surface 352, a flank surface354, and an opposite end surface 356. Unlike the at least one island 150shown in FIGS. 1-4, the end surface 352 can include be a planar surfacethat is at an angle with respect to the flank surface 354 and notgenerally perpendicular to the flank surface 354. The end surface 352can be angled such that its planar surface slopes downward toward acenter of the surface 304. The opposite end surface 356 can be a planarsurface that can be substantially perpendicular to the flank surface354. The at least one island 350 can be disposed in the pocket 310 ofthe substrate 302. The at least one island 350 can be disposed in thepocket 310 of the substrate 302 so that the end surface 352 of the atleast one island 350 protrudes away from the surface 304 of thesubstrate 302 and away from the interior of the substrate 302, the flanksurface 354 extends into the interior of the substrate 302, and theopposite end surface 356 is disposed within the interior of thesubstrate 302. The end surface 352 can be a cutting surface, or the endsurface 352 and the flank surface 354 together can form a cuttingsurface.

In the construction shown in FIGS. 8-10, there are three islands 350spaced equally apart from each other and equidistant from a center ofthe surface 304. However, in other constructions, there may be more orless than the three islands 350 shown. Also, the exact position of eachof the island 350 with respect to each other or the center of thesurface 304 can be different from that shown in FIGS. 8-10. Also, theexact size of the islands 350 can be different. The exact number andsize of islands 350 and the exact position for each of the islands 350can depend on, for example, the application of the cutter assembly 300.

Turning to FIGS. 11-13, the cutter assembly 400 can have a substrate 402with a generally cylindrical shape. The substrate 402 can have a surface404. The surface 404 can be an end surface. The substrate 402 can alsohave a flank surface 406. The surface 404 can be substantiallyperpendicular to the flank surface 406. The flank surface 406 can meetthe surface 404 so that a common boundary between the surface 404 andthe flank surface 406 defines a peripheral edge 408 of the surface 404.The surface 404 can be a substantially planar surface. The flank surface406 can provide the substrate 402 with a generally circularcross-sectional shape. In other embodiments, the substrate 402 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 402 can include a pocket 410. The pocket 410 can have anopening 412. The opening 412 can be disposed on the surface 404 of thesubstrate 402. The pocket 410 can extend from the opening 412 on thesurface 404 to an interior of the substrate 402. The pocket 410 can havea shape that can receive at least a portion of the at least one island450.

The at least one island 450 can have a generally cylindrical shape. Theat least one island 450 can have an end surface 452, a flank surface454, and an opposite end surface 456. Unlike the at least one island 150shown in FIGS. 1-4, the end surface 452 can include a concavity thatcurves toward the opposite surface 456. The opposite end surface 456 canbe a planar surface that can be substantially perpendicular to the flanksurface 454. The at least one island 450 can be disposed in the pocket410 of the substrate 402. The at least one island 450 can be disposed inthe pocket 410 of the substrate 402 so that the end surface 452 of theat least one island 450 protrudes away from the surface 404 of thesubstrate 402 and towards the interior of the substrate 402, the flanksurface 454 extends into the interior of the substrate 402, and theopposite end surface 456 is disposed within the interior of thesubstrate 402. The end surface 452 can be a cutting surface, or the endsurface 452 and the flank surface 454 together can form a cuttingsurface.

In the construction shown in FIGS. 11-13, there are three islands 450spaced equally apart from each other and equidistant from a center ofthe surface 404. However, in other constructions, there may be more orfewer than the three islands 450 shown. Also, the exact position of eachof the island 450 with respect to each other or the center of thesurface 404 can be different from that shown in FIGS. 11-13. Also, theexact size of the islands 450 can be different. The exact number andsize of islands 450 and the exact position for each of the islands 450can depend on, for example, the application of the cutter assembly 400.In another exemplary embodiment, different types of islands may be used.As an example, convex and concave islands may be used in the samecutter.

Turning to FIG. 14, the cutter assembly 500 can have a substrate 502with a generally cylindrical shape. The substrate 502 can have a surface504. The surface 504 can be an end surface. The substrate 502 can alsohave a flank surface 506. The surface 504 can be substantiallyperpendicular to the flank surface 506. The flank surface 506 can meetthe surface 504 so that a common boundary between the surface 504 andthe flank surface 506 defines a peripheral edge 508 of the surface 504.The surface 504 can be a substantially planar surface. The flank surface506 can provide the substrate 502 with a generally circularcross-sectional shape. In other embodiments, the substrate 502 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 502 can include a pocket 510. The pocket 510 can have anopening 512. The opening 512 can be disposed on the surface 504 of thesubstrate 502. The pocket 510 can extend from the opening 512 on thesurface 504 to an interior of the substrate 502. The pocket 510 can havea shape that can receive at least a portion of the at least one island550.

The at least one island 550 can have a generally cylindrical shape. Theat least one island 550 can have an end surface 552, a flank surface,and an opposite end surface. Unlike the at least one island 150 shown inFIGS. 1-4, the at least one island 550 can have a cross-sectional shapethat can be generally semi-circular. The at least one island 550 can bedisposed in the pocket 510 of the substrate 502. The at least one island550 can be disposed in the pocket 510 of the substrate 502 so that theend surface 552 can be generally co-planar with the surface 504 of thesubstrate 502, the flank surface extends into the interior of thesubstrate 502, and the opposite end surface is disposed within theinterior of the substrate 502. The end surface 552 can alternativelyhave a convexity such that the end surface 552 can protrude from thesurface 504 of the substrate 502. In a further alternative, the endsurface 552 can have a concavity such that the end surface 552 can sagfrom the surface 504 toward an interior of the substrate 502. The endsurface 552 can be a cutting surface, or the end surface 552 and theflank surface together can form a cutting surface.

In the construction shown in FIG. 14, there are three islands 550 spacedequally apart from each other and equidistant from a center of thesurface 504. However, in other constructions, there may be more or lessthan the three islands 550 shown. Also, the exact position of each ofthe island 550 with respect to each other or the center of the surface504 can be different from that shown in FIG. 14. Also, the exact size ofthe islands 550 can be different. The exact number and size of islands550 and the exact position for each of the islands 550 can depend on,for example, the application of the cutter assembly 500.

Turning to FIG. 15, the cutter assembly 600 can have a substrate 602with a generally cylindrical shape. The substrate 602 can have a surface604. The surface 604 can be an end surface. The substrate 602 can alsohave a flank surface 606. The surface 604 can be substantiallyperpendicular to the flank surface 606. The flank surface 606 can meetthe surface 604 so that a common boundary between the surface 604 andthe flank surface 606 defines a peripheral edge 608 of the surface 604.The surface 604 can be a substantially planar surface. The flank surface606 can provide the substrate 602 with a generally circularcross-sectional shape. In other embodiments, the substrate 602 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 602 can include a pocket 610. The pocket 610 can have anopening 612. The opening 612 can be disposed on the surface 604 of thesubstrate 602. The pocket 610 can extend from the opening 612 on thesurface 604 to an interior of the substrate 602. The pocket 610 can havea shape that can receive at least a portion of the at least one island650.

The at least one island 650 can have a generally cylindrical shape. Theat least one island 650 can have an end surface 652, a flank surface,and an opposite end surface. Unlike the at least one island 150 shown inFIGS. 1-4, the at least one island 650 can have a cross-sectional shapethat can be generally ovular. The at least one island 650 can bedisposed in the pocket 610 of the substrate 602. The at least one island650 can be disposed in the pocket 610 of the substrate 602 so that theend surface 652 can be generally co-planar with the surface 604 of thesubstrate 602, the flank surface extends into the interior of thesubstrate 602, and the opposite end surface is disposed within theinterior of the substrate 602. The end surface 652 can alternativelyhave a convexity such that the end surface 652 can protrude from thesurface 604 of the substrate 602. In a further alternative, the endsurface 652 can have a concavity such that the end surface 652 can sagfrom the surface 604 toward an interior of the substrate 602. The endsurface 652 can be a cutting surface, or the end surface 652 and theflank surface together can form a cutting surface.

In the construction shown in FIG. 15, there are three islands 650 spacedequally apart from each other and equidistant from a center of thesurface 604. However, in other constructions, there may be more or lessthan the three islands 650 shown. Also, the exact position of each ofthe island 650 with respect to each other or the center of the surface604 can be different from that shown in FIG. 15. Also, the exact size ofthe islands 650 can be different. The exact number and size of islands650 and the exact position for each of the islands 650 can depend on,for example, the application of the cutter assembly 600.

Turning to FIG. 16 the cutter assembly 700 can have a substrate 702 witha generally cylindrical shape. The substrate 702 can have a surface 704.The surface 704 can be an end surface. The substrate 702 can also have aflank surface 706. The surface 704 can be substantially perpendicular tothe flank surface 706. The flank surface 706 can meet the surface 704 sothat a common boundary between the surface 704 and the flank surface 706defines a peripheral edge 708 of the surface 704. The surface 704 can bea substantially planar surface. The flank surface 706 can provide thesubstrate 702 with a generally circular cross-sectional shape. In otherembodiments, the substrate 702 can have a cross-sectional shape that canbe triangular, can be similar to a polygon, and/or can have any regularor irregular shape besides circular.

The substrate 702 can include a pocket 710. The pocket 710 can have anopening 712. The opening 712 can be disposed on the surface 704 of thesubstrate 702. The pocket 710 can extend from the opening 712 on thesurface 704 to an interior of the substrate 702. The pocket 710 can havea shape that can receive at least a portion of the at least one island750.

The at least one island 750 can have a generally cylindrical shape inone exemplary embodiment. The at least one island 750 may have agenerally polygonal shape in another exemplary embodiment. The at leastone island 750 can have an end surface 752, a flank surface, and anopposite end surface. Unlike the at least one island 150 shown in FIGS.1-4, the at least one island 750 can have a cross-sectional shape thatcan be generally triangular. In other embodiments, the at least oneisland 750 can have a cross-sectional shape that can be similar to apolygon, and/or can have any regular or irregular shape. The at leastone island 750 may be disposed in the pocket 710 of the substrate 702.The at least one island 750 may be disposed in the pocket 710 of thesubstrate 702 so that the end surface 752 can be generally co-planarwith the surface 704 of the substrate 702, the flank surface extendsinto the interior of the substrate 702, and the opposite end surface isdisposed within the interior of the substrate 702. The end surface 752can alternatively have a convexity such that the end surface 752 canprotrude from the surface 704 of the substrate 702. In a furtheralternative, the end surface 752 can have a concavity such that the endsurface 752 can sag from the surface 704 toward an interior of thesubstrate 702. The end surface 752 can be a cutting surface, or the endsurface 752 and the flank surface together can form a cutting surface.

In the construction shown in FIG. 16, there are three islands 750 spacedequally apart from each other and equidistant from a center of thesurface 704. However, in other constructions, there may be more or lessthan the three islands 750 shown. Also, the exact position of each ofthe island 750 with respect to each other or the center of the surface704 can be different from that shown in FIG. 16. Also, the exact size ofthe islands 750 can be different. The exact number and size of islands750 and the exact position for each of the islands 750 can depend on,for example, the application of the cutter assembly 700.

Turning to FIGS. 17-19, the cutter assembly 800 can have a substrate 802with a generally cylindrical shape. The substrate 802 can have a surface804. The surface 804 can be an end surface. The substrate 802 can alsohave a flank surface 806. The flank surface 806 can meet the surface 804so that a common boundary between the surface 804 and the flank surface806 defines a peripheral edge 808 of the surface 804. The flank surface806 can provide the substrate 802 with a generally circularcross-sectional shape. In other embodiments, the substrate 802 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 802 can include a pocket 810. The pocket 810 can have anopening 812. The opening 812 can be disposed on the surface 804 of thesubstrate 802. The pocket 810 can extend from the opening 812 on thesurface 804 to an interior of the substrate 802. The pocket 810 can havea shape that can receive at least a portion of the at least one island850.

The at least one island 850 can have a generally cylindrical shape. Theat least one island 850 can have an end surface 852, a flank surface854, and an opposite end surface 856. Unlike the cutter assembly 100shown in FIGS. 1-4, the surface 804 of the substrate 802 and the endsurface 852 can together form a shape protruding away from the center ofthe substrate 802. Because the end surface 852 can slope downwards, theend surface 852 can meet the opposite end surface 856, and thus, theflank surface 854 may not extend the entire periphery of the end surface852. The opposite end surface 856 can be a planar surface that issubstantially perpendicular to the flank surface 854. The at least oneisland 850 can be disposed in the pocket 810 of the substrate 802. Theat least one island 850 can be disposed in the pocket 810 of thesubstrate 802 so that the end surface 852 of the at least one island 850is substantially co-planar with surface 804 of the substrate 802, theflank surface 854 extends into the interior of the substrate 802, andthe opposite end surface 856 is disposed within the interior of thesubstrate 802. The end surface 852 can alternatively have a convexitysuch that the end surface 852 can protrude from the surface 804 of thesubstrate 802. In a further alternative, the end surface 852 can have aconcavity such that the end surface 852 can sag from the surface 804toward an interior of the substrate 802. The end surface 852 can be acutting surface, or the end surface 852 and the flank surface 854together can form a cutting surface.

In the construction shown in FIGS. 17-19, there are three islands 850spaced equally apart from each other and equidistant from a center ofthe surface 804. However, in other constructions, there may be more orless than the three islands 850 shown. Also, the exact position of eachof the island 850 with respect to each other or the center of thesurface 804 can be different from that shown in FIGS. 17-19. Also, theexact size of the islands 850 can be different. The exact number andsize of islands 850 and the exact position for each of the islands 850can depend on, for example, the application of the cutter assembly 800.

Turning to FIGS. 20-22, the cutter assembly 900 can have a substrate 902with a generally cylindrical shape. The substrate 902 can have a surface904. The surface 904 can be an end surface. The substrate 902 can alsohave a flank surface 906. The flank surface 906 can meet the surface 904so that a common boundary between the surface 904 and the flank surface906 defines a peripheral edge 908 of the surface 904. The flank surface906 can provide the substrate 902 with a generally circularcross-sectional shape. In other embodiments, the substrate 902 can havea cross-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular.

The substrate 902 can include a pocket 910. The pocket 910 can have anopening 912. The opening 912 can be disposed on the surface 904 of thesubstrate 902. The pocket 910 can extend from the opening 912 on thesurface 904 to an interior of the substrate 902. The pocket 910 can havea shape that can receive at least a portion of the at least one island950.

The at least one island 950 can have a generally cylindrical shape. Theat least one island 950 can have an end surface 952, a flank surface954, and an opposite end surface 956. Unlike the cutter assembly 100shown in FIGS. 1-4, the surface 904 of the substrate 902 and the endsurface 952 can together form a shape protruding away from the center ofthe substrate 902. Also, the surface 904 and the end surface 952protrude less from the center of the substrate 902 than the cutterassembly 800 shown in FIGS. 17-19. Because the end surface 952 can slopedownwards, the end surface 952 can meet the opposite end surface 956,and thus, the flank surface 954 may not extend the entire periphery ofthe end surface 952. The opposite end surface 956 can be a planarsurface that is substantially perpendicular to the flank surface 954.The at least one island 950 can be disposed in the pocket 910 of thesubstrate 902. The at least one island 950 can be disposed in the pocket910 of the substrate 902 so that the end surface 952 of the at least oneisland 950 is substantially co-planar with surface 904 of the substrate902, the flank surface 954 extends into the interior of the substrate902, and the opposite end surface 956 is disposed within the interior ofthe substrate 902. The end surface 952 can alternatively have aconvexity such that the end surface 952 can protrude from the surface904 of the substrate 902. In a further alternative, the end surface 952can have a concavity such that the end surface 952 can sag from thesurface 904 toward an interior of the substrate 902. The end surface 952can be a cutting surface, or the end surface 952 and the flank surface954 together can form a cutting surface.

In the construction shown in FIGS. 20-22, there are three islands 950spaced equally apart from each other and equidistant from a center ofthe surface 904. However, in other constructions, there may be more orless than the three islands 950 shown. Also, the exact position of eachof the island 950 with respect to each other or the center of thesurface 904 can be different from that shown in FIGS. 20-22. Also, theexact size of the islands 950 can be different. The exact number andsize of islands 950 and the exact position for each of the islands 950can depend on, for example, the application of the cutter assembly 900.

Turning to FIGS. 23-25, the cutter assembly 1000 can have a substrate1002 with a generally cylindrical shape. The substrate 1002 can have asurface 1004. The surface 1004 can be an end surface. The substrate 1002can also have a flank surface 1006. The flank surface 1006 can meet thesurface 1004 so that a common boundary between the surface 1004 and theflank surface 1006 defines a peripheral edge 1008 of the surface 1004.The flank surface 1006 can provide the substrate 1002 with a generallycircular cross-sectional shape. In other embodiments, the substrate 1002can have a cross-sectional shape that can be triangular, can be similarto a polygon, and/or can have any regular or irregular shape besidescircular.

The substrate 1002 can include a pocket 1010. The pocket 1010 can havean opening 1012. The opening 1012 can be disposed on the surface 1004 ofthe substrate 1002. The pocket 1010 can extend from the opening 1012 onthe surface 1004 to an interior of the substrate 1002. The pocket 1010can have a shape that can receive at least a portion of the at least oneisland 1050.

The at least one island 1050 can have a generally cylindrical shape. Theat least one island 1050 can have an end surface 1052, a flank surface1054, and an opposite end surface 1056. Unlike the cutter assembly 100shown in FIGS. 1-4, the surface 1004 of the substrate 1002 and the endsurface 1052 can together form a shape protruding towards the center ofthe substrate 1002. Because the end surface 1052 can slope downwards,the end surface 1052 can meet the opposite end surface 1056, and thus,the flank surface 1054 may not extend the entire periphery of the endsurface 1052. The opposite end surface 1056 can be a planar surface thatis substantially perpendicular to the flank surface 1054. The at leastone island 1050 can be disposed in the pocket 1010 of the substrate1002. The at least one island 1050 can be disposed in the pocket 1010 ofthe substrate 1002 so that the end surface 1052 of the at least oneisland 1050 is substantially co-planar with surface 1004 of thesubstrate 1002, the flank surface 1054 extends into the interior of thesubstrate 1002, and the opposite end surface 1056 is disposed within theinterior of the substrate 1002. The end surface 1052 can alternativelyhave a convexity such that the end surface 1052 can protrude from thesurface 1004 of the substrate 1002. In a further alternative, the endsurface 1052 can have a concavity such that the end surface 1052 can sagfrom the surface 1004 toward an interior of the substrate 1002. The endsurface 1052 can be a cutting surface, or the end surface 1052 and theflank surface 1054 together can form a cutting surface.

In the construction shown in FIGS. 23-25, there are three islands 1050spaced equally apart from each other and equidistant from a center ofthe surface 1004. However, in other constructions, there may be more orless than the three islands 1050 shown. Also, the exact position of eachof the island 1050 with respect to each other or the center of thesurface 1004 can be different from that shown in FIGS. 23-25. Also, theexact size of the islands 1050 can be different. The exact number andsize of islands 1050 and the exact position for each of the islands 1050can depend on, for example, the application of the cutter assembly 1000.

Turning to FIGS. 26-28, the cutter assembly 1100 can have a substrate1102 with a generally cylindrical shape. The substrate 1102 can have asurface 1104. The surface 1104 can be an end surface. The surface 1104can be a substantially planar surface. The substrate 1102 can also havea flank surface 1106. The surface 1104 can be substantiallyperpendicular to the flank surface 1106. The flank surface 1106 can meetthe surface 1104 so that a common boundary between the surface 1104 andthe flank surface 1106 defines a peripheral edge 1108 of the surface1104. The flank surface 1106 can provide the substrate 1102 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1102 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1102 can include a pocket 1110. The pocket 1110 may havean opening 1112. The opening 1112 may be disposed on the surface 1104 ofthe substrate 1102. The pocket 1110 may extend from the opening 1112 onthe surface 1104 to an opposite opening 1114 on an opposite end surface1116 of the substrate 1102. The pocket 1110 can have a shape that canreceive at least a portion of the at least one island 1150.

The at least one island 1150 can have a generally truncated conicalshape. The at least one island 1150 can have an end surface 1152, aflank surface 1154, and an opposite end surface 1156. Unlike the cutterassembly 100 shown in FIGS. 1-4, the end surface 1152 can be larger thanopposite end surface 1156 so that the flank surface 1154 is disposed atan angle with respect to the end surface 1152. The at least one island1150 can be disposed in the pocket 1110 of the substrate 1102. The atleast one island 1150 can be disposed in the pocket 1110 of thesubstrate 1102 so that the end surface 1152 of the at least one island1150 is substantially co-planar with surface 1104 of the substrate 1102,the flank surface 1154 extends to the opposite end surface 1116 of theinterior of the substrate 1102, and the opposite end surface 1156 issubstantially coplanar with opposite end surface 1116. The end surface1152 can alternatively have a convexity such that the end surface 1152can protrude from the surface 1104 of the substrate 1102. In a furtheralternative, the end surface 1152 can have a concavity such that the endsurface 1152 can sag from the surface 1104 toward an interior of thesubstrate 1102. The end surface 1152 can be a cutting surface, or theend surface 1152 and the flank surface 1154 together can form a cuttingsurface.

In the construction shown in FIGS. 26-28, there are three islands 1150spaced equally apart from each other and equidistant from a center ofthe surface 1104. However, in other constructions, there may be more orless than the three islands 1150 shown. Also, the exact position of eachof the island 1150 with respect to each other or the center of thesurface 1104 can be different from that shown in FIGS. 26-28. Also, theexact size of the islands 1150 can be different. The exact number andsize of islands 1150 and the exact position for each of the islands 1150can depend on, for example, the application of the cutter assembly 1100.

Turning to FIGS. 29-31, the cutter assembly 1200 can have a substrate1202 with a generally cylindrical shape. The substrate 1202 can have asurface 1204. The surface 1204 can be an end surface. The surface 1204can be a substantially planar surface. The substrate 1202 can also havea flank surface 1206. The surface 1204 can be substantiallyperpendicular to the flank surface 1206. The flank surface 1206 canprovide the substrate 1202 with a generally circular cross-sectionalshape. In other embodiments, the substrate 1202 can have across-sectional shape that can be triangular, can be similar to apolygon, and/or can have any regular or irregular shape besidescircular. However, the surface 1204 and the flank surface 1206 may notmeet. Instead, the substrate 1202 can include a pocket 1210 so that theflank surface 1206 can extend to one side of an opening 1212 for apocket 1210, and the surface 1204 can form another side of the opening1212 for the pocket 1210. The pocket 1210 can extend from the opening1212 towards an interior of the substrate 1202. The pocket 1210 can havea shape that can receive at least a portion of the at least one island1250.

The at least one island 1250 can have a generally ring-like shape. Theat least one island 1250 can have an end surface 1252, a flank surface1254, and an opposite end surface 1256. The flank surface 1254 can besubstantially perpendicular to the end surface 1252, the opposite endsurface 1256, or both. Unlike the cutter assembly 100 shown in FIGS.1-4, the at least one island can include a second flank surface 1258.The second flank surface 1258 can be substantially perpendicular to theend surface 1252, the opposite end surface 1256, or both. The at leastone island 1250 can be disposed in the pocket 1210 of the substrate1202. The at least one island 1250 can be disposed in the pocket 1210 ofthe substrate 1202 so that the end surface 1252 of the at least oneisland 1250 can be substantially co-planar with surface 1204 of thesubstrate 1202, the flank surface 1254 can extend between the flanksurface 1206 of the substrate 1202 and the surface 1250, the oppositeend surface 1256 can be disposed in the pocket 1210, and the secondflank surface 1256 can be disposed in the pocket 1210. The end surface1252 can alternatively have a convexity such that the end surface 1252can protrude from the surface 1204 of the substrate 1202. In a furtheralternative, the end surface 1252 can have a concavity such that the endsurface 1252 can sag from the surface 1204 toward an interior of thesubstrate 1202. The end surface 1252 can be a cutting surface, or theend surface 1252 and the flank surface 1254 together can form a cuttingsurface.

In the construction shown in FIGS. 29-31, there is one island 1250disposed equidistant from a center of the surface 1204. However, inother constructions, there may be more or less than the one island 1250shown. Also, the exact position of the island 1250 with respect to thecenter of the surface 1204 can be different from that shown in FIGS.29-31. Also, the exact size of the islands 1250 can be different. Theexact number and size of islands 1250 and the exact position for each ofthe islands 1250 can depend on, for example, the application of thecutter assembly 1200.

Turning to FIGS. 32-34, the cutter assembly 1300 can have a substrate1302 with a generally cylindrical shape. The substrate 1302 can have asurface 1304. The surface 1304 can be an end surface. The surface 1304can be a substantially planar surface. The substrate 1302 can also havea flank surface 1306. The surface 1304 can be substantiallyperpendicular to the flank surface 1306. The flank surface 1306 can meetthe surface 1304 so that a common boundary between the surface 1304 andthe flank surface 1306 defines a peripheral edge 1308 of the surface1304. The flank surface 1306 can provide the substrate 1302 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1302 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1302 can include one or more pockets 1310. The one or morepockets 1310 can each have an opening 1312. The openings 1312 can bedisposed on the surface 1304 of the substrate 1302. The openings 1312can be disposed such that one of the openings 1312 is surrounded byanother of the openings 1312. The one or more pockets 1310 can extendfrom the openings 1312 on the surface 1304 to an interior of thesubstrate 1302. The one or more pockets 1310 can have a shape that canreceive at least a portion of the at least one island 1350.

The at least one island 1350 can have a generally ring-like shape. Theat least one island 1350 can have an end surface 1352, a flank surface1354, and an opposite end surface 1356. The flank surface 1354 can besubstantially perpendicular to the end surface 1352, the opposite endsurface 1356, or both. Unlike the cutter assembly 100 shown in FIGS.1-4, the at least one island can include a second flank surface 1358.The second flank surface 1358 can be substantially perpendicular to theend surface 1352, the opposite end surface 1356, or both. The at leastone island 1350 can be disposed in the one or more pockets 1310 of thesubstrate 1302. The at least one island 1350 can be disposed in the oneor more pockets 1310 of the substrate 1302 so that the end surface 1352of the at least one island 1350 can be substantially co-planar withsurface 1304 of the substrate 1302, the flank surface 1354 and thesecond flank surface 1358 can extend into an interior of the substrate1302, and the opposite end surface 1356 can be disposed in the one ormore pockets 1310. The end surface 1352 can alternatively have aconvexity such that the end surface 1352 can protrude from the surface1304 of the substrate 1302. In a further alternative, the end surface1352 can have a concavity such that the end surface 1352 can sag fromthe surface 1304 toward an interior of the substrate 1302. The endsurface 1352 can be a cutting surface, or the end surface 1352 and theflank surface 1354 together can form a cutting surface.

In the construction shown in FIGS. 32-34, there are two islands 1350disposed concentrically with respect to a center of the surface 1304.However, in other constructions, there may be more or less than the twoislands 1350 shown. Also, the exact position of the islands 1350 withrespect to the center of the surface 1304 can be different from thatshown in FIGS. 32-34. Also, the exact size of the islands 1350 can bedifferent. The exact number and size of islands 1350 and the exactposition for each of the islands 1350 can depend on, for example, theapplication of the cutter assembly 1300.

Turning to FIGS. 35-37, the cutter assembly 1400 can have a substrate1402 with a generally cylindrical shape. The substrate 1402 can have asurface 1404. The surface 1404 can be an end surface. The surface 1404can be a substantially planar surface. The substrate 1402 can also havea flank surface 1406. The flank surface 1406 can include a concavitythat curves towards an interior of the substrate 1402 or bulges awayfrom the substrate 1402. The flank surface 1406 can provide thesubstrate 1402 with a generally circular cross-sectional shape. In otherembodiments, the substrate 1402 can have a cross-sectional shape thatcan be triangular, can be similar to a polygon, and/or can have anyregular or irregular shape besides circular. However, the surface 1404and the flank surface 1406 may not meet. Instead, the substrate 1402 caninclude a pocket 1410 so that the flank surface 1406 can extend to oneside of an opening 1412 for a pocket 1410, and the surface 1404 can formanother side of the opening 1412 for the pocket 1410. The pocket 1410can extend from the opening 1412 towards an interior of the substrate1402. The pocket 1410 can have a shape that can receive at least aportion of the at least one island 1450.

The at least one island 1450 can have a generally ring-like shape. Theat least one island 1450 can have an end surface 1452, a flank surface1454, and an opposite end surface 1456. The flank surface 1454 can besubstantially perpendicular to the end surface 1452, the opposite endsurface 1456, or both. Unlike the cutter assembly 100 shown in FIGS.1-4, the at least one island can include a second flank surface 1458.The second flank surface 1458 can be substantially perpendicular to theend surface 1452, the opposite end surface 1456, or both. The at leastone island 1450 can be disposed in the pocket 1410 of the substrate1402. The at least one island 1450 can be disposed in the pocket 1410 ofthe substrate 1402 so that the end surface 1452 of the at least oneisland 1450 can be substantially co-planar with surface 1404 of thesubstrate 1402, the flank surface 1454 can extend between the flanksurface 1406 of the substrate 1402 and the surface 1450, the oppositeend surface 1456 can be disposed in the pocket 1410, and the secondflank surface 1456 can be disposed in the pocket 1410. The end surface1452 can alternatively have a convexity such that the end surface 1452can protrude from the surface 1404 of the substrate 1402. In a furtheralternative, the end surface 1452 can have a concavity such that the endsurface 1452 can sag from the surface 1404 toward an interior of thesubstrate 1402. The end surface 1452 can be a cutting surface, or theend surface 1452 and the flank surface 1454 together can form a cuttingsurface.

In the construction shown in FIGS. 35-37, there is one island 1450disposed equidistant from a center of the surface 1404. However, inother constructions, there may be more or less than the one island 1450shown. Also, the exact position of the island 1450 with respect to thecenter of the surface 1404 can be different from that shown in FIGS.35-37. Also, the exact size of the islands 1450 can be different. Theexact number and size of islands 1450 and the exact position for each ofthe islands 1450 can depend on, for example, the application of thecutter assembly 1400.

Turning to FIGS. 38-40, the cutter assembly 1500 can have a substrate1502 with a generally cylindrical shape. The substrate 1502 can have asurface 1504. The surface 1504 can be an end surface. The substrate 1502can also have a flank surface 1506. The surface 1504 can besubstantially perpendicular to the flank surface 1506. The flank surface1506 can meet the surface 1504 so that a common boundary between thesurface 1504 and the flank surface 1506 defines a peripheral edge 1508of the surface 1504. The surface 1504 can be a substantially planarsurface. The flank surface 1506 can provide the substrate 1502 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1502 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1502 can include a pocket 1510. The pocket 1510 can havean opening 1512. The opening 1512 can be disposed on the surface 1504,the edge 1508, and the flank surface 1506 of the substrate 1502. Thepocket 1510 can extend from the opening 1512 on the surface 1504, theedge 1508, and the flank surface 1506 to an interior of the substrate1502. The pocket 1510 can have a shape that can receive at least aportion of the at least one island 1550.

The at least one island 1550 can have a generally cylindrical shape. Theat least one island 1550 can have an end surface 1552, a flank surface1554, and an opposite end surface 1556. The end surface 1552 can be aplanar surface that can be substantially perpendicular to the flanksurface 1554. The opposite end surface 1556 can also be a planar surfacethat is substantially perpendicular to the flank surface 1554. The atleast one island 1550 can be disposed in the pocket 1510 of thesubstrate 1502. The at least one island 1550 can be disposed in thepocket 1510 of the substrate 1502 so that the end surface 1552 of the atleast one island 1550 is substantially co-planar with surface 1504 ofthe substrate 1502, the flank surface 1554 extends into the interior ofthe substrate 1502 and protrudes beyond the flank surface 1506 of thesubstrate 1502, and the opposite end surface 1556 is at least partiallydisposed within the interior of the substrate 1502. The end surface 1552can alternatively have a convexity such that the end surface 1552 canprotrude from the surface 1504 of the substrate 1502. In a furtheralternative, the end surface 1552 can have a concavity such that the endsurface 1552 can sag from the surface 1504 toward an interior of thesubstrate 1502. The end surface 1552 can be a cutting surface, or theend surface 1552 and the flank surface 1554 together can form a cuttingsurface. In another exemplary embodiment, at least one island 1550 mayintersect the periphery edge.

In the construction shown in FIGS. 38-40, there are three islands 1550spaced equally apart from each other and equidistant from a center ofthe surface 1504. However, in other constructions, there may be more orless than the two islands 1550 shown. Also, the exact position of theislands 1550 with respect to each other or the center of the surface1504 may be different from that shown in FIGS. 38-40. Also, the exactsize of the islands 1550 can be different. The exact number and size ofislands 1550 and the exact position for each of the islands 1550 candepend on, for example, the application of the cutter assembly 1500.

For example, turning to FIGS. 41-43, there are four islands 1550 spacedequally apart from each other and equidistant from a center of thesurface 1504.

Turning to FIGS. 44-46, the cutter assembly 1600 can have a substrate1602 with a generally cylindrical shape. The substrate 1602 can have asurface 1604. The surface 1604 can be an end surface. The substrate 1602can also have a flank surface 1606. The surface 1604 can besubstantially perpendicular to the flank surface 1606. The flank surface1606 can meet the surface 1604 so that a common boundary between thesurface 1604 and the flank surface 1606 defines a peripheral edge 1608of the surface 1604. The surface 1604 can be a substantially planarsurface. The flank surface 1606 can provide the substrate 1602 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1602 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1602 can include a pocket 1610 and portion 1614 that canextend the pocket 1610 beyond the flank surface 1606 of the substrate1602. The portion 1614 can be shaped to receive a portion of the atleast one island 1650. As best seen in FIG. 46, the portion 1614 canalso be shaped to include a curve between the portion 1614 and the flanksurface 1606 of the substrate 1602, and the portion 1614 can furtherinclude another curve where the portion 1614 receives the at least oneisland 1650. The pocket 1610 can have an opening 1612. The opening 1612can be disposed on the surface 1604, the edge 1608, the flank surface1606, and the portion 1614 of the substrate 1602. The pocket 1610 canextend from the opening 1612 on the surface 1604, the edge 1608, and theflank surface 1606 to an interior of the substrate 1602. The pocket 1610can have a shape that can receive at least a portion of the at least oneisland 1650.

The at least one island 1650 can have a generally cylindrical shape. Theat least one island 1650 can have an end surface 1652, a flank surface1654, and an opposite end surface 1656. The end surface 1652 can be aplanar surface that can be substantially perpendicular to the flanksurface 1654. The opposite end surface 1656 can also be a planar surfacethat is substantially perpendicular to the flank surface 1654. The atleast one island 1650 can be disposed in the pocket 1610 of thesubstrate 1602. The at least one island 1650 can be disposed in thepocket 1610 of the substrate 1602 so that the end surface 1652 of the atleast one island 1650 is substantially co-planar with surface 1604 ofthe substrate 1602. The at least one island 1650 can also be disposed inthe pocket 1610 of the substrate 1602 so that the flank surface 1654extends into the interior of the substrate 1602 and protrudes beyond theflank surface 1606 of the substrate 1602. The at least one island 1650can be further disposed in the pocket 1610 of the substrate 1602 so thatthe opposite end surface 1656 is at least partially disposed within theinterior of the substrate 1602 and partially disposed on the portion1614. The end surface 1652 can alternatively have a convexity such thatthe end surface 1652 can protrude from the surface 1604 of the substrate1602. In a further alternative, the end surface 1652 can have aconcavity such that the end surface 1652 can sag from the surface 1604toward an interior of the substrate 1602. The end surface 1652 can be acutting surface, or the end surface 1652 and the flank surface 1654together can form a cutting surface.

In the construction shown in FIGS. 44-46, there are three islands 1650spaced equally apart from each other and equidistant from a center ofthe surface 1604. However, in other constructions, there may be more orless than the two islands 1650 shown. Also, the exact position of theislands 1650 with respect to each other or the center of the surface1604 can be different from that shown in FIGS. 44-46. Also, the exactsize of the islands 1650 can be different. The exact number and size ofislands 1650 and the exact position for each of the islands 1650 candepend on, for example, the application of the cutter assembly 1600.

Turning to FIGS. 47-49, the cutter assembly 1700 can have a substrate1702 with a generally cylindrical shape. The substrate 1702 can have twoparts 1702 a and 1702 b. The substrate part 1702 a can have a surface1704 a and an opposite surface 1705 a that can be opposite to surface1704 a. The surface 1704 a can be an end surface, and the surface 1705 acan be another end surface. The substrate part 1702 a can also have aflank surface 1706 a. The surface 1704 a, the surface 1705 a, or bothsurfaces 1704 a and 1705 a can be substantially perpendicular to theflank surface 1706 a. The flank surface 1706 a can meet the surface 1704a so that a common boundary between the surface 1704 a and the flanksurface 1706 a defines a peripheral edge 1708 a of the surface 1704 a.The surface 1704 a can be a substantially planar surface. The surface1705 a can also be a substantially planar surface. The flank surface1706 a can provide the substrate part 1702 a with a generally circularcross-sectional shape. In other embodiments, the substrate part 1702 acan have a cross-sectional shape that can be triangular, can be similarto a polygon, and/or can have any regular or irregular shape besidescircular.

The substrate part 1702 b can have a surface 1704 b. The surface 1704 bcan be an end surface. The surface 1704 b can be shaped to receivesurface 1705 a of substrate part 1702 a. The substrate 1702 b can alsohave a flank surface 1706 b. The surface 1704 b can be substantiallyperpendicular to the flank surface 1706 b. The flank surface 1706 b canmeet the surface 1704 b so that a common boundary between the surface1704 b and the flank surface 1706 b defines a peripheral edge 1708 b ofthe surface 1704 b. The surface 1704 b can be a substantially planarsurface. The flank surface 1706 b can provide the substrate part 1702 bwith a generally circular cross-sectional shape. In other embodiments,the substrate part 1702 b can have a cross-sectional shape that can betriangular, can be similar to a polygon, and/or can have any regular orirregular shape besides circular.

The substrate par 1702 a can include a pocket 1710. The pocket 1710 canhave an opening 1712. The opening 1712 can be disposed on the surface1705 a of the substrate part 1702 a. The pocket 1710 can extend from theopening 1712 on the surface 1704 to an interior of the substrate part1702 a. The pocket 1710 can have a shape that can receive at least aportion of the at least one island 1750.

The at least one island 1750 can have a generally cylindrical shape. Theat least one island 1750 can have an end surface 1752, a flank surface1754, and an opposite end surface 1756. The end surface 1752 can be aplanar surface that can be substantially perpendicular to the flanksurface 1754. The opposite end surface 1756 can also be a planar surfacethat is substantially perpendicular to the flank surface 1754. The atleast one island 1750 can be disposed in the pocket 1710 of thesubstrate part 1702 a. The at least one island 1750 can be disposed inthe pocket 1710 of the substrate part 1702 a so that the opposite endsurface 1756 of the at least one island 1750 is substantially co-planarwith surface 1705 a of the substrate part 1702 a, the flank surface 1754extends into the interior of the substrate part 1702 a, and the endsurface 1752 is disposed within the interior of the substrate part 1702a. The end surface 1752 can be a cutting surface, or the end surface1752 and the flank surface 1754 together can form a cutting surface.

In the construction shown in FIGS. 47-49, there are three islands 1750spaced equally apart from each other and equidistant from a center ofthe surface 1705 a and equidistant from the surface 1704 a. However, inother constructions, there may be more or less than the three islands1750 shown. Also, the exact position of each of the island 1750 withrespect to each other, the center of the surface 1705 a, or the surface1704 a can be different from that shown in FIGS. 47-49. Also, the exactsize of the islands 1750 can be different. The exact number and size ofislands 1750 and the exact position for each of the islands 1750 candepend on, for example, the application of the cutter assembly 1700.

Turning to FIGS. 50-52, the cutter assembly 1800 can have a substrate1802 with a generally cylindrical shape. The substrate 1802 can have asurface 1804. The surface 1804 can be an end surface. The substrate 1802can also have a flank surface 1806. The surface 1804 can besubstantially perpendicular to the flank surface 1806. The flank surface1806 can meet the surface 1804 so that a common boundary between thesurface 1804 and the flank surface 1806 defines a peripheral edge 1808of the surface 1804. The surface 1804 can be a substantially planarsurface. The flank surface 1806 can provide the substrate 1802 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1802 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1802 can include a pocket 1810. The pocket 1810 can havean opening 1812. The opening 1812 can be disposed on the surface 1804 ofthe substrate 1802. The pocket 1810 can extend from the opening 1812 onthe surface 1804 to an interior of the substrate 1802. The pocket 1810can have a shape that can receive at least a portion of the at least oneisland 1850.

The at least one island 1850 can have a generally cylindrical shape. Theat least one island 1850 can have an end surface 1852, a flank surface1854, and an opposite end surface 1856. The end surface 1852 can be aplanar surface that can be substantially perpendicular to the flanksurface 1854. The opposite end surface 1856 can also be a planar surfacethat is substantially perpendicular to the flank surface 1854. The atleast one island 1850 can be disposed in the pocket 1810 of thesubstrate 1802. The at least one island 1850 can be disposed in thepocket 1810 of the substrate 1802 so that the end surface 1852 of the atleast one island 1850 is not co-planar with surface 1804 of thesubstrate 1802 but below the surface 1804 of the substrate. A substratepart 1858 can be disposed in the pocket 1810 on the end surface 1852 ofthe at least one island 1850. The substrate part 1858 can also extend tothe opening 1812 of the pocket 1810 and can be substantially co-planarwith the surface 1804 of the substrate 1802. The substrate part 1858 canbe made of the same material as the substrate 1802. Alternatively, thesubstrate part 1858 and the substrate 1802 can be made from differentmaterials. The at least one island 1850 can also be disposed in thepocket 1810 of the substrate 1802 so that the flank surface 1854 extendsinto the interior of the substrate 1802 and the end surface 1852 isdisposed within the interior of the substrate 1802. The end surface 1852can alternatively have a convexity such that the end surface 1852 canprotrude from the surface 1804 of the substrate 1802. In a furtheralternative, the end surface 1852 can have a concavity such that the endsurface 1852 can sag from the surface 1804 toward an interior of thesubstrate 1802. The end surface 1852 can be a cutting surface, or theend surface 1852 and the flank surface 1854 together can form a cuttingsurface.

In the construction shown in FIGS. 50-52, there are three islands 1850spaced equally apart from each other and equidistant from a center ofthe surface 1804. However, in other constructions, there may be more orless than the three islands 1850 shown. Also, the exact position of eachof the island 1850 with respect to each other or the center of thesurface 1804 can be different from that shown in FIGS. 50-52. Also, theexact size of the islands 1850 can be different. The exact number andsize of islands 1850 and the exact position for each of the islands 1850can depend on, for example, the application of the cutter assembly 1800.Also in the construction shown in FIGS. 50-52, there are three substrateparts 1858 of the same thickness. However, in other constructions, theremay be substrate parts 1858 of different thickness and the exactposition of the each of the island 1850 with respect to surface 1804 canbe different from that shown in FIGS. 50-52.

Turning to FIGS. 53-55, the cutter assembly 1900 can have a substrate1902 with a generally cylindrical shape. The substrate 1902 can have asurface 1904. The surface 1904 can be an end surface. The substrate 1902can also have a flank surface 1906. The surface 1904 can besubstantially perpendicular to the flank surface 1906. The flank surface1906 can meet the surface 1904 so that a common boundary between thesurface 1904 and the flank surface 1906 defines a peripheral edge 1908of the surface 1904. The surface 1904 can be a substantially planarsurface. The flank surface 1906 can provide the substrate 1902 with agenerally circular cross-sectional shape. In other embodiments, thesubstrate 1902 can have a cross-sectional shape that can be triangular,can be similar to a polygon, and/or can have any regular or irregularshape besides circular.

The substrate 1902 can include a groove 1914. The groove 1914 may beable to delay contact of the substrate 1902 when the at least one island1950 is substantially worn. The groove 1914 can disposed on the flanksurface 1906. The groove 1914 can penetrate towards an interior of thesubstrate 1902. The groove 1914 can be shaped like the letter “V”, anopen polygonal shape, or an open semi-circle as shown in FIGS. 53-55.The groove 1914 can have a length that extends throughout the flanksurface 1906 so that the groove 1914 extends entirely around an outerperiphery of the substrate 1902. Alternatively, the groove 1914 canextend only through a portion of the flank surface 1906 so that thegroove 1914 extends only partially around an outer periphery of thesubstrate 1902. The groove 1914 can extend substantially straight ormeander across the flank surface 1906.

The substrate 1902 can include a pocket 1910. The pocket 1910 can havean opening 1912. The opening 1912 can be disposed on the surface 1904 ofthe substrate 1902. The pocket 1910 can extend from the opening 1912 onthe surface 1904 to an interior of the substrate 1902. The pocket 1910can have a shape that can receive at least a portion of the at least oneisland 1950.

The at least one island 1950 can have a generally cylindrical shape. Theat least one island 1950 can have an end surface 1952, a flank surface1954, and an opposite end surface 1956. The end surface 1952 can be aplanar surface that can be substantially perpendicular to the flanksurface 1954. The opposite end surface 1956 can also be a planar surfacethat is substantially perpendicular to the flank surface 1954. The atleast one island 1950 can be disposed in the pocket 1910 of thesubstrate 1902. The at least one island 1950 can be disposed in thepocket 1910 of the substrate 1902 so that the end surface 1952 of the atleast one island 1950 is substantially co-planar with surface 1904 ofthe substrate 1902, the flank surface 1954 extends into the interior ofthe substrate 1902, and the opposite end surface 1956 is disposed withinthe interior of the substrate 1902. The end surface 1952 canalternatively have a convexity such that the end surface 1952 canprotrude from the surface 1904 of the substrate 1902. In a furtheralternative, the end surface 1952 can have a concavity such that the endsurface 1952 can sag from the surface 1904 toward an interior of thesubstrate 1902. The end surface 1952 can be a cutting surface, or theend surface 1952 and the flank surface 1954 together can form a cuttingsurface.

In the construction shown in FIGS. 53-55, there are three islands 1950spaced equally apart from each other and equidistant from a center ofthe surface 1904. However, in other constructions, there may be more orless than the three islands 1950 shown. Also, the exact position of eachof the island 1950 with respect to each other or the center of thesurface 1904 can be different from that shown in FIGS. 35-55. Also, theexact size of the islands 1950 can be different. The exact number andsize of islands 1950 and the exact position for each of the islands 1950can depend on, for example, the application of the cutter assembly 1900.

Referring to FIG. 56, a method 2000 of manufacturing the cutter with atleast one island is shown. The method 2000 can include providing atleast one island, step 2002; treating the at least one island, step2004; providing a substrate, step 2006; forming a surface circumscribedby a peripheral edge on the substrate, step 2008; forming at least onepocket with an opening on the surface and spaced apart from theperipheral edge such that the at least one pocket extends from theopening towards an interior of the substrate and has a shape thatengages with the at least one island, step 2010; disposing the at leastone island in the at least one pocket, step 2012; and coupling the atleast one island to the at least one pocket, step 2014. Alternatively,in step 2010, the at least one pocket can be formed within thesubstrate.

The step of providing the at least one island can further compriseforming the at least one island from a polycrystalline diamond, acemented carbide, a polycrystalline cubic boron nitride (cBN)superabrasive, a ceramic, a metal, a metal alloy, and/or combinationsthereof made from at least one of a high pressure high temperatureprocess, a chemical vapor deposition process, and a physical vapordeposition process. The step of providing the at least one island canfurther comprise forming the at least one island from a portion of apolycrystalline diamond.

The method 2000 can further comprise coating the at least one island.The method 2000 can alternatively further comprise encasing the at leastone island. The method can further comprise coupling the at least islandto the at least one pocket. The at least one island can be coupled tothe at least one pocket by press fit, gluing, brazing, bonding,clamping, mechanical interlocking, or welding.

The step of treating the at least one island can further comprisepartially leaching the at least one island. Alternatively, the step oftreating the at least one island can further comprise substantiallyfully leaching the at least one island.

The step of disposing the at least one island in the at least one pocketcan further comprise disposing the at least one island such that acutting surface of the at least one island is substantially flush withthe surface of the substrate. The step of disposing the at least oneisland in the at least one pocket can further comprise disposing the atleast one island such that a cutting surface of the at least one islandprotrudes outward from the surface of the substrate. The step ofdisposing the at least one island in the at least one pocket furthercomprises disposing the at least one island such that a cutting surfaceof the at least one island projects towards the interior of thesubstrate.

The method 2000 can also further comprise providing a cutting surfacethat has a generally circular shape on the at least one island.Alternatively, the method 2000 can further comprise providing a cuttingsurface that has a generally ovalular shape on the at least one island.In another alternative, the method 2000 can further comprise

providing a cutting surface that has a generally triangular shape. Inyet another alternative, the method 2000 can further comprise providinga cutting surface that has a generally polygonal shape.

The method 2000 can further comprise forming at least one other pocketon the surface symmetrically with respect to the at least one pocket;and disposing at least one other island in the at least one otherpocket. Alternatively, the method 2000 can further comprise forming atleast one other pocket on the surface unsymmetrically with respect tothe at least one pocket and disposing at least one other island in theat least one other pocket. In another alternative, the method 2000 canfurther comprise forming at least one other pocket on the surface spacedapart from the at least one pocket and disposing at least one otherisland in the at least one other pocket. In yet another alternative, themethod 2000 can further comprise forming at least one other pocket onthe surface with a second opening conjoined with the opening of the atleast one pocket and disposing at least one other island in the at leastone other pocket.

The method 2000 can further include forming a planar surface, a concavesurface, a dome-shaped surface, a chiseled surface, or a wavy surfacewith the surface of the substrate and a cutting surface of the at leastone island.

The step of providing the substrate can include forming the substrate soas to provide a substrate 102 . . . 1902, as described above and asshown in FIGS. 1-55. Also, the step of providing a substrate can furthercomprise forming the substrate from carbide, tungsten carbide composite,tungsten carbide composite held up by an eta-phase, polycrystallinecubic boron nitride, polycrystalline diamond, or a combination of two ormore of the aforementioned.

The step of providing the at least one pocket can be include forming theat least one pocket so as to provide at least one pocket 110 . . . 1910,as described above and as shown in FIGS. 1-55.

The step of providing the at least one island can be include forming theat least one island so as to provide at least one island 150 . . . 1950,as described above and as shown in FIGS. 1-55. The step of providing theat least one island can further comprise forming the at least one islandfrom polycrystalline diamond, polycrystalline diamond compact, diamond,cubic boron nitride, polycrystalline cubic boron nitride,diamond-silicon carbide composite material, polycrystalline diamondcomposite, chemical vapor deposition diamond, or a combination of two ormore of the aforementioned.

Referring to FIG. 57, a method 2100 of manufacturing the cutter with atleast one island is shown. The method 2000 of manufacturing can includeproviding a PCD piece from a high pressure, high temperature (HPHT)process in a step 2102. Alternatively, the PCD can be provided from achemical vapor deposition (CVD), a physical vapor deposition (PVD), orsome other suitable process. The method can also include forming asmaller PCD part from the PCD piece, step 2104. The method can furtherinclude fully or partially leaching the cobalt out of the PCD part, step2106. The PCD part can then be coated with, for example, a tungstencoating, or the PCD part can be press fitted into a casing, such as ametal casing. The PCD part with or without a coating or a casing canthen be coupled to the substrate, step 2108. The coupling can be by, forexample, gluing, brazing, bonding, welding, clamping, mechanicallocking, or any other suitable coupling.

More specifically, the fabrication process or method may be categorizedinto a first group (Group I) which may comprise methods of preparing theindividual components in a final state. The final state herein may referto the component's chemical composition, shape, mechanical properties,density phase distribution and content may be finalized with littlechanges, assembling them together to form a final embodiment. Anothergroup (Group II) may adopt another route to pre-assemble the semi-madecomponents (in green body form, not the final state), then followed byone-step sintering or fabricating the pre-assembly.

In group I method or process, a pocket in substrate, such as a pocket inthe sintered carbide which may be made of Co—WC, Ni—WC, or WC basedmaterials containing other cubic carbides, such as titanium carbide,niobium carbide, tantalum carbide, vanadium carbide, chromium carbide,molybdenum carbide, for example, may be machined with the methods suchas wire electro discharge machining (EDM), electro discharge grinding(EDG), milling, drilling, grinding, turning, laser ablation and/or lasercutting. The pocket thus made may be to a specific size to house theisland.

Another exemplary method to form the pocket or housing cavity may be toform a net shape during the fabrication process of the substrate. Thefabrication process may proceed as follows: at least one displacementmay be to fabricate with the similar shape of the island from asacrificial material. The sacrificial materials may comprise graphite,hexagonal boron nitride (h-BN), salt, ceramics, minerals and/or themixtures thereof. The displacement part may be pre-fabricated with anyof the methods including: machining, sintering, pressing, gluing. Thedisplacement part thus fabricated may have a similar shape as the islandbut not exactly the same dimension in order to account for thedimensional changes during fabrication process (like shrinkage duringHPHT pressing/sintering). The displacement part may then be assembledinto the substrate green body and may go through the same fabricationprocess such as sintering. After the process, the displacement part maybe removed from the finished substrate body to form a cavity, a notch, ahousing or a pocket for the island. The removal methods may include,water dissolving of soluble displacement materials like salt/h-BN,milling/grinding insolvable materials like ceramics, graphite. Necessarysuccessive cleaning process like sand blasting, grinding, machining maybe needed to clean the cavity thus formed to a desirable dimension.

Another exemplary method to fabricate the substrate with at least onepocket to house the island may be to build a substrate with the cavityin it in a single step. To do this, the substrate green body prior tofinal sintering stage may have the at least one cavity/pocket in it. Theshape of the green body is the same as that of the final sinteredsubstrate while there is difference in the absolute dimensions betweenthe substrate green body and the final sintered substrate part. Thisdifference is to account for the volumetric shrinkage during thesintering process. The green body may be made from a method likepre-compaction, die-pressing, extrusion, slurry casting. Necessarybinder agents might be adopted in the fabrication process to provide thegreen body with a desired strength. The binder agents may include, wax,polyvinyl butyrate (PVB), polyvinyl acetate (PVA), polyvinyl chloride(PVC), polyethylene glycol (PEG). Other machining steps upon the greenbody aforementioned may also include if necessary, i.e. milling,drilling, turning, grinding, or coring. The substrate green body may besubjected to the carbide fabrication process like sintering to achievethe final geometric dimension and physical/chemical properties. Themethod may be a one-step method to have the pocket built into thesubstrate. Successive cleaning process might be needed to clean theburrs and/or other debris from the pocket wall/bottom also to a desiredfinal dimension.

All the aforementioned methods of fabricating the substrate may also beapplied to fabricate a partial substrate. The partial substrate may belater on assembled to the other part of the substrate and make up thewhole substrate. However, the same idea and essence of the invention maybe applied to the whole substrate and/or part of the substrate. Also thesubstrate materials may be WC containing materials. The substrate may bemade of materials including single crystalline diamond, polycrystallinediamond, single crystalline cubic boron nitride, polycrystalline cubicboron nitride, WC, VersiMax®, thermally stable diamond, cermet and/orceramics.

One of the methods to form the net shape of islands may be to use apreformed foil barrier, such as metal barriers. The preformed foilbarriers may be made of materials that may function as the separationwalls between the islands during the high-pressure high-temperature(HPHT) process. Such materials may comprise a refractory metal, such asZr, Ta, Mo, V, Nb, stainless steel, graphite, minerals and grafoil,casting solidified slurry, plastically formed borders, or mechanicallyoppressed the mixture thereof. The barrier are arranged or preformed insuch a way as to form compartments to house island materials or pre-madeisland green bodies into it. The island materials may be loaded into thecompartments in powder form, or slurry, or colloidal form. The pre-madeisland green bodies may be made from pre-compaction, die-pressing,extrusion and/or slurry casting. Then the island materials and/or greenbodies together with the preformed barriers are subject to the HPHTprocess to achieve the desired shape and chemical/physical properties.The islands thus formed may be separated with successive processing.

Another way of forming island is to first fabricate a dense chunk ofisland materials. The fabrication methods may include HPHT sintering,atmospheric pressure sintering, pressurized sintering, press sintering,CVD, PVD. The island may be machined or cut from the chunk into thefinal desired shape and dimensions. The machining methods and thecutting methods comprise sawing, coring, slicing, drilling, turning,grinding, milling, wire EDM cutting, EDG, laser cutting.

The island aforementioned may comprise a single crystalline diamond,polycrystalline diamond, single crystalline cubic boron nitride, andpolycrystalline cubic boron nitride, WC, VersiMax®, thermally stablediamond, cermet, ceramics and/or WC.

There may be several ways to assemble the pre-formed island andsubstrate. In one exemplary embodiment for the pre-formed substratehaving at least one pocket and the at least one island, the final islandcutter may be assembled via brazing, welding or soldering. To assure theadherence between the substrate pocket and the island coating on eitherthe island and or substrate, brazing, welding, soldering process may beused. Such coating may comprise tungsten, silicon, titanium, silver,copper, chromium, tantalum, vanadium, niobium, zirconium, molybdenum,iron, nickel, cobalt. The brazing, welding, soldering agent may containgold, silver, copper, zinc, tin, silicon, titanium, chromium, vanadium,nickel, cobalt, iron, platinum, palladium, tungsten, for example.

The brazing, welding, soldering temperature may be in the range of 500°C. to 1500° C., for example. The range may be 650° C. to 1250° C. in oneexemplary embodiment. In another exemplary embodiment the range may be700° C. to 1000° C., for example. The at least one island with optionalcoating is seated in the at least one pocket of the substrate as per thedesired orientation to form an assembly with at least one island in thesubstrate. In another exemplary embodiment, coating may be on anintermediate layer between the substrate and the island. Brazing,welding or soldering agent and heat may be applied to the assembly. Theintimate bonding may form between the at least one island and the atleast one substrate to a desirable mechanical strength or chemicalproperties. The heat source or heating method may be from radiationheating, microwave heating, torch heating, laser heating, electrical archeating, infrared heating, induction heating, electrical resistanceheating, conduction heating, ultrasonic heating, convection heating forexample.

During the heating process optional atmospheric condition may be neededto facilitate the brazing, welding or soldering. Such atmosphericcondition includes inert gas, reforming gas, reducing atmosphere,ambient atmosphere, oxidizing atmosphere, high-pressure atmosphere, orvacuum atmosphere. External pressure may also be applied to facilitatethe brazing, welding or soldering.

Another method to assemble the at least one island and the substratewith at least one pocket into an embodiment may be with press fitting.The island may be slightly bigger than the pocket in the substrate. Withthe negative interference between the island and the pocket in thesubstrate, a net force may be applied to retain the island in thesubstrate once the island is pressed into the pocket of the substrate.To facilitate the process, certain heating or cooling upon the substratewith at least one pocket or the island might be adopted. Also coating orintermediate layer between the substrate and the island may be employedto manage the local stress condition between the island and thesubstrate.

Yet another method to achieve the assembly of island and substrate maybe to use mechanical locking. The substrate and island geometries aredesigned in such that after the island fits in the pocket of thesubstrate, the island may be secured with mechanical locking. Suchgeometries may include trenches, steps, slopes, curves. Other than thelocking from the geometric design of island and/or substrate, theexternal mechanical locking methods may also be adopted, such as pins,screws, caps. The mechanical locking may be realized via geometricdesigns on the substrate and the island like trenches, steps, slopes, orcurves.

There may be many ways to fabricate island cutter from island andsubstrate green bodies. One exemplary embodiment to build a substratewith the cavity in it. To do this, the substrate green body prior to thefinal HPHT sintering stage may have the at least one cavity/pocket init. The shape of the green body is the same as that of the sinteredsubstrate while there is difference in the absolute dimensions betweenthe substrate green body and the final sintered substrate part. Thedifference may be to account for the volumetric shrinkage during thefinal HPHT sintering process. The green body thus made may be made fromany known methods like pre-compaction, die-pressing, extrusion, slurrycasting. Necessary binder agents might be adopted in the fabricationprocess to provide the green body with desired strength. The binderagents may include wax, PVB, PVA, PVC, PEG. Other machining steps uponthe substrate green body aforementioned may also be included ifnecessary, i.e. milling, drilling, turning, grinding, coring.

The aforementioned methods of fabrication of the substrate green bodymay also be applied to fabricate partial substrate green body. Thepartial substrate green body may later be assembled to the other partsof the substrate green bodies and make up the whole substrate greenbody. However, the same idea and essence of the invention may be appliedto the whole substrate or part of the substrate. Also the substratematerials may be Co—WC, Ni—WC and WC based materials containing othercubic carbides like titanium carbide, niobium carbide, tantalum carbide,vanadium carbide, chromium carbide, molybdenum carbide. The substratemay be made of any materials including single crystalline diamond,polycrystalline diamond, single crystalline cubic boron nitride,polycrystalline cubic boron nitride, WC, Versimax®, thermally stablediamond, cermet and/or ceramics.

To fabricate the at least one island green body, the shape of the atleast one island green body may be the same as that of the finalsintered island while there is difference in the absolute dimensionsbetween the island green body and the final sintered island part. Thisdifference may be to account for the volumetric shrinkage during thefinal HPHT sintering process. The green body may be made from a methodlike pre-compaction, die-pressing, extrusion, slurry casting. Necessarybinder agents might be adopted in the fabrication process to provide thegreen body with a desired strength. The binder agents include wax, PVB,PVA, PVC, PEG. Other machining steps upon the island green bodyaforementioned may also be included if necessary, i.e. milling,drilling, turning, grinding, coring. The aforementioned methods offabrication of the island green body may also be applied to fabricatethe partial island green body. The partial island green body may lateron be assembled to the other parts of the island green bodies and makeup the whole island green body. However the same idea and essence of theinvention may be applied to the whole island and/or part of the island.

Also the island materials may not be limited to single crystallinediamond, polycrystalline diamond, single crystalline cubic boronnitride, polycrystalline cubic boron nitride, WC, VersiMax®, thermallystable diamond, cermet and/or ceramics. The island may be made of anymaterials including Co—WC, Ni—WC and WC based materials containing othercubic carbides like titanium carbide, niobium carbide, tantalum carbide,vanadium carbide, chromium carbide, molybdenum carbide.

The substrate green body with at least one pocket and the at least oneisland green body may be assembled into a cutter green body assembly.The assembly may then be subjected to HPHT process to be sintered intoone embodiment. Optional sintering additives or aids may be added tofacilitate the sintering process. The sintering additive and/or aid maycomprise Group VIII metals, cobalt, iron, nickel or metalloid silicon,for example. The sintering temperature range may be between 900° C. to2300° C. in one exemplary embodiment. In another exemplary embodiment,the sintering temperature may be between 1000° C. to 2000° C. In yetanother exemplary embodiment, the sintering temperature may be from1200° C. to 1800° C. In further another exemplary embodiment, thesintering temperature may range from 1300° C. to 1600° C. Pressure rangemay be 5 GPa to 20 GPa in one exemplary embodiment. In another exemplaryembodiment, the pressure range may be between 6 GPa to 15 GPa. In yetanother exemplary embodiment, the pressure range may be from 6.5 GPa to10 GPa, for example. The sintered embodiment might go through successivefinishing steps to the desired final dimension like grinding, lapping,turning, polishing, bonding, heat treatment and/or chamfering.

In an exemplary embodiment of fabricating island cutters from islandgreen body or powder and sintered substrate, the at least one islandgreen body or island powder may be put into the at least one pocket ofthe sintered substrate to form a pre-sintering cutter assembly. Theassembly may be then subjected to HPHT process to be sintered into oneembodiment. Optional sintering additives and/or aids may be added tofacilitate the sintering process. The sintering additive or aid maycomprise of Group VIII metals, cobalt, iron, nickel or metalloidsilicon. The sintering temperature range may be between 900° C. to 2300°C. in one exemplary embodiment. In another exemplary embodiment, thesintering temperature may be between 1000° C. to 2000° C. In yet anotherexemplary embodiment, the sintering temperature may be from 1200° C. to1800° C. In further another exemplary embodiment, the sinteringtemperature may range from 1300° C. to 1600° C. Pressure range may be 5GPa to 20 GPa in one exemplary embodiment. In another exemplaryembodiment, the pressure range may be between 6 GPa to 15 GPa. In yetanother exemplary embodiment, the pressure range may be from 6.5 GPa to10 GPa, for example. The sintered embodiment might go through successivefinishing steps to the desired final dimension like grinding, lapping,turning, polishing, bonding, heat treatment and/or chamfering.

For the purposes of promoting an understanding of the principles of theinvention, reference has been made to the embodiments illustrated in thedrawings, and specific language has been used to describe theseembodiments. However, no limitation of the scope of the invention isintended by this specific language, and the invention should beconstrued to encompass all embodiments that would normally occur to oneof ordinary skill in the art. The terminology used herein is for thepurpose of describing the particular embodiments and is not intended tobe limiting of exemplary embodiments of the invention.

The use of any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No item or component is essential to the practice ofthe invention unless the element is specifically described as“essential” or “critical”. The words “mechanism” and “element” are usedbroadly and are not limited to mechanical or physical embodiments, butmay include software routines in conjunction with processors, etc. Itwill also be recognized that the terms “comprises,” “comprising,”“includes,” “including,” “has,” and “having,” as used herein, arespecifically intended to be read as open-ended terms of art. The use ofthe terms “a” and “an” and “the” and similar referents in the context ofdescribing the invention (especially in the context of the followingclaims) are to be construed to cover both the singular and the plural,unless the context clearly indicates otherwise. In addition, it shouldbe understood that although the terms “first,” “second,” etc. may beused herein to describe various elements, these elements should not belimited by these terms, which are only used to distinguish one elementfrom another. Furthermore, recitation of ranges of values herein aremerely intended to serve as a shorthand method of referring individuallyto each separate value falling within the range, unless otherwiseindicated herein, and each separate value is incorporated into thespecification as if it were individually recited herein.

Numerous modifications and adaptations will be readily apparent to thoseof ordinary skill in this art without departing from the spirit andscope of the present invention as defined by the following claims.Therefore, the scope of the invention is defined not by the detaileddescription of the invention but by the following claims, and alldifferences within the scope will be construed as being included in theinvention.

Although described in connection with preferred embodiments thereof, itwill be appreciated by those skilled in the art that additions,deletions, modifications, and substitutions not specifically describedmay be made without department from the spirit and scope of theinvention as defined in the appended claims.

What is claimed is:
 1. A method of fabricating a cutting element having at least one island structure in at least one pocket of a substrate, comprising: building the substrate with at least one pocket; putting the at least one island into the at least one pocket in the substrate to form an assembly, the at least one island is not in a final state, wherein in the final state, chemical composition, shape, phase distribution and content, density and mechanical properties are finalized without changes; and subjecting the assembly to a final fabrication process to form the said cutting element and achieve the final state of the cutting element and at least one island in at least one pocket.
 2. The method according to claim 1, wherein the at least one island is island material powder.
 3. The method according to claim 1, wherein the at least one island material is an island green body.
 4. The method according to claim 1, wherein the final fabrication process is an HPHT process.
 5. The method according to claim 4, wherein the HPHT process uses sintering additive or aid to facilitate the HPHT process.
 6. The method according to claim 5, wherein the sintering additive or aid comprises Group VIII metals, cobalt, iron, nickel or metalloid silicon.
 7. The method according to claim 4, wherein the HTHP process is under temperature range of from 900° C. to 2300° C.
 8. The method according to claim 4, wherein the HTHP process is under pressure range of from 3 GPa to 20 GPa.
 9. The method according to claim 4, wherein the HTHP process is under pressure range of from 0.01 GPa to 20 GPa.
 10. The method according to claim 1, wherein the substrate is at least one of WC, polycrystalline diamond, single crystalline diamond, polycrystalline cubic boron nitride, single crystalline boron nitride, cermet, ceramics, thermally stable diamond, and diamond composite.
 11. The method according to claim 1, wherein the at least one pocket in the substrate is formed by at least one of EDM, EDG, milling, drilling, grinding, turning, laser ablation and laser cutting.
 12. The method according to claim 1, wherein the at least one pocket in the substrate is formed by removal of a pre-formed displacement part in the substrate after a fabrication process.
 13. The method according to claim 12, wherein the pre-formed displacement is made of at least one of graphite, hexagonal boron nitride (h-BN), salt, ceramics, minerals.
 14. The method according to claim 12, wherein the removal includes at least one of dissolving soluble displacement materials, milling, and grinding insolvable materials.
 15. The method according to claim 1, wherein the substrate green body with at least one pocket is pre-formed with at least one method of pre-compaction, die-pressing, extrusion, slurry casting.
 16. The method according to claim 9, wherein the at least one pocket in the substrate green body is pre-formed with at least one method of milling, drilling, turning, grinding, coring.
 17. A method of fabricating a cutting element having at least one island structure in at least one pocket of a substrate, comprising: putting at least one island into at least one pocket in a substrate to form an assembly, the at least one island is not in a final state, wherein in the final state, chemical composition, shape, phase distribution and content, density and mechanical properties are finalized without changes; and subjecting the assembly to a high temperature high pressure sintering process to form the said cutting element and achieve the final state of the cutting element and at least one island in at least one pocket.
 18. The method according to claim 17, wherein the at least one island material is an island green body.
 19. The method according to claim 17, wherein the HPHT sintering process uses sintering additive or aid to facilitate the HPHT process.
 20. The method according to claim 19, wherein the sintering additive or aid comprises Group VIII metals, cobalt, iron, nickel or metalloid silicon. 